Power assist wagon

ABSTRACT

A power assist system for a wagon is provided. The power assist system provides a rotational force to one or more drive wheels under certain conditions to provide propulsion for the wagon. The power assist wagon preferably includes a drive system for providing the rotational force to the drive wheel, a control system for determining when the drive system should be activated and how much propulsion assist to provide to the drive wheel, and a power system for providing power to the drive system. The power assist wagon may also have a safety cut-off system to preclude the drive system from providing a rotational force to the drive wheel  16  even when the system is in the “on” mode.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/234,383, filed Sep. 29, 2015, which is expresslyincorporated herein by reference and made a part hereof.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

TECHNICAL FIELD

The present disclosure generally relates to a wagon, and moreparticularly, to a wagon having a power assist feature.

BACKGROUND

Wagons, including folding wagons, are well known in the art. Further,powered drive mechanisms for vehicles and wagons are known in the art.While such wagons and drive mechanisms according to the prior artprovide a number of advantages, they nevertheless have certainlimitations. The disclosed embodiments seek to overcome certain of theselimitations and other drawbacks of the prior art, and to provide newfeatures not heretofore available. A full discussion of the features andadvantages of the various embodiments is deferred to the followingdetailed description, which proceeds with reference to the accompanyingdrawings.

SUMMARY

According to one embodiment, the disclosed subject technology relates toa drive mechanism and drive control system. The drive mechanism anddrive control system may be incorporated into a wagon, including afoldable wagon that is convertible from an open, unfolded or useposition (i.e., an open configuration) to a closed or folded position(i.e., a closed configuration).

The disclosed subject technology further relates to a power assistsystem for a wagon, comprising: a wagon body, the wagon body having aplurality of wheels connected thereto, at least one of the plurality ofwheels being a driven wheel; a handle having a distal end and a proximalend, the proximal end of the handle being pivotally connected to thewagon body; a handle grip adjacent a distal end of the handle; a controlsystem in one of the handle and the handle grip, the control systemcomprising a sensor to sense a load being applied to the handle gripthat moves at least a portion of the handle grip axially with respect tothe proximal end of the handle; a drive system comprising a motormechanically connected to the driven wheel; and, a microcontrollerobtaining an input signal from the control system and providing anoutput signal to the drive system to selectively drive the driven wheelof the wagon.

The disclosed subject technology further relates to a power assistsystem for a wagon, comprising: a wagon body, the wagon body having aplurality of wheels connected thereto, at least one of the plurality ofwheels being a driven wheel; the driven wheel rotatingly connected to anaxle; a drive system comprising a motor mechanically connected to thedriven wheel, the drive system further comprising a motor controllerelectrically connected to the motor; a handle having a distal end and aproximal end, the proximal end of the handle being pivotally connectedto the wagon body; a handle grip adjacent a distal end of the handle,the handle grip having an internal sensor; and, a microcontrollerelectrically connected to the sensor and the motor controller, themicrocontroller obtaining a signal from the sensor, and based on thesignal from the sensor the microcontroller sending a signal to the motorcontroller to speed up or slow down the motor.

The disclosed subject technology further relates to a power assistsystem for a wagon, comprising: a wagon body, the wagon body having aplurality of wheels connected thereto, at least one of the plurality ofwheels being a driven wheel; a handle having a distal end and a proximalend, the proximal end of the handle being pivotally connected to thewagon body and the distal end having a handle grip; a control sensor inthe handle; a drive system comprising a motor mechanically connected tothe driven wheel; a microcontroller obtaining an input signal from thecontrol sensor and providing an output signal to the drive system toselectively drive the driven wheel of the wagon; and, a safety cut-offsystem connected to the handle, the safety cut-off system comprising asafety-control switch electrically connected to the microcontroller, themicrocontroller adjusting the signal sent to the drive system based on astate of the safety-control switch.

The disclosed subject technology further relates to a control systemthat comprises a sensor to determine a load applied to the handle grip,wherein the load must be greater than a predetermined minimum thresholdabove zero pounds for the drive system to provide initial propulsion tothe drive wheel.

The disclosed subject technology further relates to a micro switch aspart of the control system, the micro switch being opened when a loadgreater than a predetermined minimum threshold above zero pounds isapplied to the handle grip, the micro switch being closed when a loadless than the predetermined minimum threshold is applied to the handle,and the microcontroller obtaining a signal from the micro switch as towhether the micro switch is open or closed.

The disclosed subject technology further relates to a spring adjacentthe distal end of the handle, wherein the spring provides a force thatmust be overcome for the handle grip to move axially with respect to theproximal end of the handle.

The disclosed subject technology further relates to a control systemincluding a remaining battery life indicator on the handle.

The disclosed subject technology further relates to a control systemincluding an on/off switch, wherein the motor is electricallydisconnected from the motor controller when the on/off switch is in theoff state.

The disclosed subject technology further relates to a control systemwherein the sensor within the handle senses an axial load being appliedto the handle by a user.

The disclosed subject technology further relates to a safety cut-offsystem connected to the handle, the safety cut-off system comprising asafety-control switch electrically connected to the microcontroller, andthe microcontroller adjusting the signal sent to the drive system basedon a state of the safety-control switch. In one embodiment themicrocontroller turns off the drive system when the handle is below apreset angle and when the handle is above a preset angle. In oneembodiment the safety cut-off switch is adjacent the proximal end of thehandle.

The disclosed subject technology further relates to a drive system thatcomprises a motor and a motor controller, and wherein the motorcontroller sends a signal to the motor to control output of the motor.

The disclosed subject technology further relates to a rechargeablebattery connected to the wagon, the battery providing a source of powerfor the drive system. In one embodiment the battery is removable fromthe wagon, and the battery can be recharged on an auxiliary chargerseparate from the wagon.

The disclosed subject technology further relates to a control systemwherein to provide an initial signal to the motor to speed up the sensormust sense a load greater than a predetermined minimum threshold abovezero pounds.

It is understood that other embodiments and configurations of thesubject technology will become readily apparent to those skilled in theart from the following detailed description, wherein variousconfigurations of the subject technology are shown and described by wayof illustration. As will be realized, the subject technology is capableof other and different configurations and its several details arecapable of modification in various other respects, all without departingfrom the scope of the subject technology. Accordingly, the drawings anddetailed description are to be regarded as illustrative in nature andnot as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present disclosure, it will now be described by way ofexample, with reference to the accompanying drawings in whichembodiments of the disclosures are illustrated and, together with thedescriptions below, serve to explain the principles of the disclosure.

FIG. 1 is a top rear perspective view of a power assist wagon accordingto one embodiment.

FIG. 2 is a top front perspective view of a power assist wagon accordingto one embodiment.

FIG. 3 is bottom rear perspective view of a power assist wagon accordingto one embodiment.

FIG. 4A is a perspective view of one embodiment of a handle for a powerassist wagon.

FIG. 4B is a partial cross-sectional view of the handle of FIG. 4A aboutlines 4B-4B.

FIG. 5A is a partial perspective view of one embodiment of an inputmodule in the handle of the power assist wagon.

FIG. 5B is a front view of the input module in the handle of the powerassist wagon of FIG. 5A, with the handle shown in the unactuated state.

FIG. 5C is an enlarged view of a portion of the input module in thehandle of the power assist wagon of FIGS. 5A and 5B.

FIG. 6 is a front view of the input module in the handle of the powerassist wagon of FIG. 5A, with the handle shown in the actuated state.

FIG. 7 is a front view of another embodiment of the input module in thehandle of the power assist wagon, with the handle shown in theunactuated state.

FIG. 8 is a partial cross-sectional perspective view of the input moduleof the handle as shown in FIG. 7 about lines 8-8.

FIG. 9 is a front view of the input module in the handle of the powerassist wagon of FIG. 7, with the handle shown in the actuated state.

FIG. 10 is a partial cross-sectional perspective view of the inputmodule of the handle as shown in FIG. 9 about lines 10-10.

FIG. 11 is a schematic comparing a handle force signal to the motoroutput in one embodiment of a power assist wagon.

FIG. 12A is a perspective view of one embodiment of the connectionassembly between the handle and the wagon frame, with the exterior capremoved.

FIG. 12B is a perspective view of the connection assembly between thehandle and the wagon frame of FIG. 12A, with the exterior cap attached,but including a partial cross-section through the cap and mountingcomponents.

FIG. 12C is a partial side view of the cross-sectional view of theconnection assembly between the handle and wagon frame of FIG. 12B, withthe handle in the vertical orientation.

FIG. 12D is a partial side view of the cross-sectional view of theconnection assembly between the handle and wagon frame of FIG. 12B, withthe handle lowered from the vertical orientation.

FIG. 12E is a partial side view of the cross-sectional view of theconnection assembly between the handle and wagon frame of FIG. 12B, withthe handle lowered from the vertical orientation further than theorientation in FIG. 12D.

FIG. 13 is a side view of one embodiment of the power assist wagon,showing the range of angular movement of the handle according to oneembodiment.

FIG. 14A is an exploded perspective view of one embodiment of a drivesystem for a power assist wagon.

FIG. 14B is a partial perspective view of one embodiment of a drivewheel and drive adapter for connecting the drive wheel to the drivesystem.

FIG. 14C is a cross-sectional view of the drive wheel connected to thedrive system, according to one embodiment.

FIG. 15 is a perspective view showing one embodiment for charging abattery for a power assist wagon.

FIG. 16 is a perspective view showing the removal and insertion for abattery in one embodiment of a power assist wagon.

FIG. 17 is a partial cross-sectional view of one embodiment of a batteryhousing member for a power assist wagon.

FIG. 18 is a perspective view of one embodiment of an auxiliary charginghousing for a battery for a power assist wagon.

FIG. 19A is a partial perspective schematic view illustrating the wiringconnection at the front of the wagon according to one embodiment.

FIG. 19B is a partial side schematic view illustrating the wiringconnection at the rear of the wagon according to one embodiment.

FIG. 20 is a schematic of one embodiment of a control system for thepower assist wagon.

DETAILED DESCRIPTION

While the power assist wagon discussed herein is susceptible ofembodiments in many different forms, the disclosure will show in thedrawings, and will herein describe in detail, preferred embodiments withthe understanding that the present description is to be considered as anexemplification of the principles of the power assist wagon and are notintended to limit the broad aspects of the disclosure to the embodimentsillustrated.

The power assist wagon is a product that is intended to be used byadults to provide a powered assist when pulling a wagon and when thepulling force exceeds a certain threshold.

Referring now to the figures, and initially to FIGS. 1-3, there is shownone embodiment of the power assist wagon 10. The power assist wagon 10may have a wagon body 12, a pair of front wheels 14, which may becaster-type wheels to allow for turning/steering of the wagon 10, a pairof rear wheels 16 mounted on a rear axle 18, and a handle 20 to pull andsteer the wagon 10. The wagon 10 may also have one or more seats 22provided within the interior of the wagon body 12, and a wagon canopy 24to shade the riders in the wagon 10. In one embodiment the wagon bodymay comprise a frame 26 and a removable, or permanently affixed, shell28, such as a fabric shell 28 provided in the embodiment shown inFIG. 1. Finally, the wagon 10 may be a folding wagon so that it foldsfrom an open position as shown in FIG. 1, to a closed or folded positionfor transport and storage.

As shown in FIGS. 14A-14C, one or more of the wheels, and preferably oneor more of the rear wheels 16 may be driven under certain conditions toprovide propulsion for the wagon 10. To provide the propulsion, thepower assist wagon 10 preferably includes a drive system 30 forproviding a rotational force to the drive wheel 16, a control system 32for determining when the drive system 30 should be activated and howmuch propulsion assist to provide to the drive wheel 16, and a powersystem 34 for providing power to the drive system 30. The power assistwagon 10 may also have a safety cut-off system 36 to preclude the drivesystem 30 from providing a rotational force to the drive wheel 16 evenwhen the system is in the “on” mode.

In one embodiment, the handle 20 of the wagon 10 has a telescopingfeature. Referring to FIGS. 4A and 4B, the telescoping feature ispreferably provided for by having an outer handle tube 38, an innerhandle tube 40 and a securing mechanism 42. The inner handle tube 40 cantelecopingly slide in the outer handle tube 38 to adjust the overallhandle length to the desired length. It is understood that the inner andout tubes may be reversed. Additionally, the inner handle tube 40 has aseries of spaced-apart apertures 44. The securing mechanism 42 isconnected to the outer handle tube 38 and has a spring-loaded pivotinglever 46 with a stopper 48 that is adapted to engage the apertures 44 inthe inner handle tube 40. As shown in FIG. 4B, by depressing an end ofthe pivoting lever 46 and overcoming the spring force of the spring 50,the stopper 48 is pivoted out of the aperture 44 and the inner handletube 40 can be slid inwardly or outwardly with respect to the outertuber 38 to effectuate shortening or lengthening of the handle 20. Whenthe inner handle tube 40 is relocated to the desired position, the lever46 can be released and the force of the spring 50 will push the stopper48 into the aperture 44 positioned adjacent the stopper 48. It has beendetermined that it is beneficial to have a securing mechanism 42 that isprovided on the outside of the outer and inner handle tubes 38, 40 tolimit the structure inside the central portion of the tubes 38, 40 thatcould interfere with the wires therein.

Referring also to FIGS. 2 and 4A, the distal end 52 of the handle 20 hasa hand grip portion 54 (also referred to as a handle grip portion 54 orhandle grip 54). An on/off toggle switch 56 is provided in the hand gripportion 54 of the handle 20. When the on/off toggle switch 56 is turnedto the “on” position the battery powers and turns on the microcontrollerand the motor controller. Further, in a preferred embodiment a relayconnects the motor controller with the motor. The relay is automaticallyoff when the on/off switch 56 is in the “off” position, electricallydisconnecting the motor from the motor controller. This helps to preventback-EMF and allows the motor to be turned easier manually when thewagon is not powered up. A battery indicator 58 is also preferablyprovided in the hand grip portion 54 of the handle 20. In oneembodiment, the battery indicator 58 comprises a series of lights.Preferably, five lights are provided, each light relating to 20% batterylife. Accordingly, when all five lights are illuminated the remainingbattery life is approximately 80-100%, when four of the five lights areilluminated the remaining battery life is approximately 60-80%, whenthree of the five lights are illuminated the remaining battery life isapproximately 40-60%, when two of the five lights are illuminated theremaining battery life is approximately 20-40%, and when one of the fivelights are illuminated the remaining battery life is approximately0-20%.

In a preferred embodiment, the hand grip portion 54 of the handle 20comprises a two-part clam shell structure that is fitted around thedistal end of the inner handle tube 40 and which is able to move axiallywith respect to the inner handle tube 40. The two parts of the clamshell structure of the hand grip portion 54 are fixedly connected toeach other via a plurality of fasteners to form a single hand grip 54partially around the inner handle tube 40. The hand grip portion 54 isalso movably connected to the distal end of the inner handle tube 40. Asbest shown in FIGS. 4A-11, the distal end of the inner handle tube 40has a longitudinal slot 60. One or more fasteners 62 are fitted throughthe slot 60 and connected to the opposing portions of the hand gripportions 54 as shown in FIGS. 8 and 10. The fasteners 62 provide toprevent rotational movement of the hand grip 54 with respect to theinner handle tube 40, but allow for axial/longitudinal movement of thehand grip 54 with respect to the inner handle tube 40. A plug 64 isprovided at the end of the inner handle tube 40. In one embodiment, aportion of the plug 64 is inserted into the central open portion of theinner handle tube 40 in a press fit manner. The plug 64 may also befixed in place within the inner handle tube 40 with a set screw or somealternate fixing member. In one embodiment, the plug 64 has a flange 66at a top of the plug 64 that extends past a perimeter of the innerhandle tube 40. The flange 66 may have an irregular shape such that itassists in preventing rotational movement of the inner handle tube 40with respect to the handle 20.

As shown in FIGS. 5A-10, in one embodiment a compression spring 68 ispositioned in the handle 20. In one embodiment, one end of thecompression spring 68 is fixed to or set against the fastener 62 thatpasses through the slot 60 in the inner handle tube 40, while theopposing end of the compression spring 68 is fixed against the flange 66of the plug 64 at the top of the inner handle tube 40. The compressionspring 68 operates to prevent outward axial movement of the hand grip 54in the direction of the arrows in FIGS. 6 and 9 unless a sufficientforce is applied to compress the spring 68. In one embodiment, thespring 68 is preloaded or pretensioned in place to eliminate any slop inthe system. It is understood that the spring 68 could alternately be atension spring, an elastomer spring, a plurality of belleville washers,etc., which is properly designed to provide a counter-force. There couldalso be multiple springs, symmetrically placed about the tube.

In a preferred embodiment, the handle 20 preferably houses a portion ofthe control system 32, a portion of which is referred to as the inputmodule, for the power assist wagon 10. In one embodiment, as shown inFIG. 20, the control system 32 comprises a sensor 70, an on/off toggleswitch 56, and a micro switch 72, each of which transmits signals to amicrocontroller 74. The microcontroller 74 electrically communicateswith the drive system 30, the power system 34, and the safety cut-offsystem 36. The microcontroller 74 also electrically communicates withthe power supply and the battery indicator 58. While the sensor 70 ispreferably housed in the handle grip 54, it is understood that it may beprovided anywhere on the handle 20 that moves relative to the wagon body12.

In one embodiment, as shown in FIGS. 5B-6, the sensor 70 in the handlegrip 54 comprises an encoder 76 that is fixed to the handle grip 54. Inthe normal or unactuated state, i.e., when no force is being applied tothe handle grip 54 or in the situation when a force is being applied tothe handle grip 54 but the force is less than the force to compress thespring 68, the handle grip 54 will not move relative to the inner handletube 40 (i.e., the handle tube 40 and the handle grip 54 will movetogether). Such an unactuated state of the handle grip 54 is shown inFIG. 5B. In this instance the distance from one end of the spring 68 tothe opposing end of the spring 68 is “X.” As the handle 20 is pulledagainst the movement of the wagon 10 (in the direction of the arrows inFIG. 6), if a force being applied to the handle grip 54 (i.e., the forcepulling the handle 20 in the direction of the arrows in FIG. 6) issufficient to compress the spring 68, the handle grip 54 and the encoder76 will move axially with respect to the inner handle tube 40. Oneexample of a situation where a sufficient force may be applied to thehandle grip 54 to compress the spring 68 is when the wagon is loadedwith two children and a parent is pulling the wagon up a hill. This willlikely cause the force on the handle grip 54 to compress the spring 68.The greater the load on the handle grip 54, the more the spring 68 willbe compressed and the greater the distance the handle grip 54 and theencoder 76 will move with respect to the handle tube 40. In oneembodiment, the maximum distance the spring 68 can compress isapproximately 6 mm. As shown in FIG. 6, the spring 68 is in the fullycompressed state such that the distance between the two ends of thespring 68 is identified as being a distance “Y.” In one embodiment,X−Y=approximately 6 mm, which equates to the maximum amount of travel ofthe handle grip 54 with respect to the handle tube 40. In a preferredembodiment the spring constant of the spring 68 is approximately 120lbs/in. Accordingly, because the spring 68 is pretensioned, the spring68 will begin to compress upon the application of a very low force, forexample approximately 0.5 lbs. of force, and will compress the full 6 mmupon approximately 30 lbs. of force. As the handle grip 54 and encoder76 move axially with respect to the inner handle tube 40, a linear gear78 connected to the plug 64 in the inner handle tube 40 and furthercontacting the gears 80 in the encoder 76 causes the gears 80 in theencoder 76 to rotate, as shown best in FIG. 5C, because the encodergears 80 engage the linear gear 78. When the encoder gears 80 rotate, ashaft 82 within the encoder 76 that is rotationally connected to theencoder gears 80 also rotates, thereby providing an encoder output thatcan be read by the microcontroller 74. The distance the hand grip 54moves linearly relative to the inner handle tube 40 is a direct andproportional relationship to the number of degrees the encoder shaft 82rotates. When the encoder shaft 82 is spun zero degrees (i.e., meaningthere is no movement of the handle grip 54 relative to the inner handletube 40), the microcontroller 74 reads a value of zero from the encoder76. Conversely, when the handle grip 54 is pulled and translated themaximum 6 mm relative to the inner handle tube 40, the spring 68 is alsocompressed 6 mm, the encoder shaft 82 is spun a certain number ofdegrees, and the microcontroller will read the maximum value from theencoder 76, which in one embodiment is a value of 48. In one embodiment,the encoder value that the microcontroller 74 obtains from the encoderare values from 0 to 48, which are directly proportional to the distancethe handle grip 54 is pulled relative to the inner handle tube 40.Accordingly, in one embodiment the system provides a numerical valuefrom 0 to 48 to the microcontroller 74 corresponding to the force theuser is pulling on the handle grip 54. The numerical value determined bythe encoder is obtained by the microcontroller 74 and is one of thevariables in the control algorithm used to calculate a signal, such as apulse width modulation signal, from the motor controller to the motor.While not shown, wires extend from the output terminals 85 of theencoder and down the middle of the handle tubes 38, 40 to the wiringharness 88 shown in FIG. 19A.

While an encoder is one sensor that may be used to determine thedistance moved by the hand grip 54, another method is with the use of ahall effect sensor. Referring to FIGS. 7-10, in an alternate embodimenta hall effect sensor 84 is the sensor 70 utilized in the control system.The hall effect sensor 84 outputs a varying voltage based on theproximity of the sensor 84 to magnets 86. As is understood by those ofskill in the art, the orientation of the sensor 84 as well as thenumber, strength and orientation of the magnets 86 affects the output ofthe sensor 84, e.g., resolution, accuracy, linearity, etc. The halleffect sensor 84 outputs an absolute analog voltage based on theposition of the sensor 84 relative to the magnets 86, and sends theanalog voltage to the microcontroller 74. The microcontroller 74 willmeasure the change in voltage from zero to determine the position of thehand grip 54 relative to the inner handle tube 40. An analog to digitalconverter in the microcontroller 74 converts the voltage into a digitalsignal input that will be sent to the control algorithm as describedherein.

As best shown in FIGS. 8 and 10, in this alternate embodiment, the sameinner handle tube 40 is provided with a slot 60 and the inner handletube 40 is movably fixed to the handle grip 54 to allow for movement ofthe handle grip 54 with respect to the handle tube 40, but to preventrotational movement therebetween. Similarly, the plug 64 with a flange66 is provided within at the interior top of the inner handle tube 40,however no linear gear is needed. The compression spring 68 ispretensioned between the fastener 62 and the flange 66 of the plug. Thehall effect sensor 84 is secured to the top of the plug 64, and aplurality of magnets 86 are connected and fixed in place to the handlegrip 54. Accordingly, the hall effect sensor 84 remains fixed in itslocation with respect to the handle inner handle tube 40, and themagnets 86 remain fixed in place with respect to the handle grip.Further, the magnets 86 move with the handle grip 54 as the handle grip54 is forced away from the handle inner handle tube 40 (compare FIGS. 7and 8 with FIGS. 9 and 10). In the normal or unactuated state, i.e.,when no force is being applied to the handle grip 54 or in the situationwhen a force is being applied to the handle grip 54 but the force isless than the force to compress the spring 68, the handle grip 54 willnot move relative to the inner handle tube 40 (i.e., the handle tube 40and the handle grip 54 will move together). Such an unactuated state ofthe handle grip 54 is shown in FIGS. 7 and 8. In this instance thedistance from one end of the spring 68 to the opposing end of the spring68 is “X.” As the handle 20 is pulled against the movement of the wagon10 (in the direction of the arrows in FIG. 9), if a force being appliedto the handle grip 54 (i.e., the force pulling the handle 20 in thedirection of the arrows in FIG. 9) is sufficient to compress the spring68, the handle grip 54 and the magnets 86 will move axially with respectto the inner handle tube 40. The greater the load on the handle grip 54,the more the spring 68 will be compressed and the greater the distancethe handle grip 54 and the magnets 86 will move with respect to thehandle tube 40. In one embodiment, the maximum distance the spring 68can compress when utilizing the hall effect sensor is approximately2.5-3.0 mm. As shown in FIGS. 9 and 10, the spring 68 is in the fullycompressed state such that the distance between the two ends of thespring 68 is identified as being a distance “Y.” In one embodiment,X−Y=approximately 6 mm. As the handle grip 54 and magnets 86 moveaxially with respect to the inner handle tube 40, the hall effect sensor84 provides a changing absolute analog voltage output to themicrocontroller 74. The distance the hand grip 54 moves linearlyrelative to the inner handle tube 40 is, theoretically, generally adirect and proportional relationship to the voltage output sent by thehall effect sensor 84 to the microcontroller 74. The voltage output sentby the hall effect sensor 84 to the microcontroller 74, or obtained bythe microcontroller 74 from the hall effect sensor 84, is one of thevariables in the control algorithm used to calculate a signal, such as apulse width modulation signal, from the motor controller to the motor.While not shown, wires extend from the output terminals of the halleffect sensor 84 down the middle of the handle tubes 38, 40 to thewiring harness 88 shown in FIG. 19A. Alternate types of sensors 70 todetect force include potentiometers, optical encoders, ultrasonicsensors, proximity sensors, strain gauges, accelerometers, etc. Thevoltage output value sent by the hall effect sensor 84 to themicrocontroller 74 is used in the control algorithm to control themotor.

Referring to FIGS. 5A through 10, in various embodiments the controlsystem 32 also comprises a micro switch 72, such as a momentary microswitch, within the handle grip 54. The micro switch 72 is fixedlyconnected within the handle grip 54. The micro switch 72 has a switch 90extending therefrom that engages the top of the flange 66 of the plug64. When no axial force is applied to the hand grip 54, or an axialforce less than a force that is required to compress the spring 68 isapplied to the hand grip 54, the switch 90 does not move from the closedposition and the micro switch 72 remains closed (see FIGS. 5B and 7).When an axial force greater than a force that is required to compressthe spring 68 is applied to the hand grip 54, the hand grip 54 willtranslate axially outward or away relative to the handle inner handletube 40 and the switch 90 on the micro switch 72 will open (see FIGS. 6and 9). Similarly, when the axial force greater than the force requiredto compress the spring is removed from the hand grip 54, the hand grip54 will translate axially back toward the handle inner handle tube 40and the switch 90 on the micro switch 72 will close again. Themicrocontroller 74 will obtain a signal of open or closed from the microswitch 72 depending on the state of the switch 90 of the micro switch72. The state of the switch 90 of the micro switch 72 is anothervariable in the control algorithm used to calculate a signal, such as apulse width modulation signal, from the motor controller to the motor.Additionally, in a preferred embodiment, the micro switch 72 operates toprovide a zero state value for calibration purposes during everyinstance that the handle grip 54 returns to the normal/unactuated state.For example, with a hall effect sensor 84 as the sensor 70 in the handlegrip 54, the micro switch 72 will set or calibrate the zero voltageposition of the hall effect sensor with the microcontroller 74 ever timethe handle grip 54 is released and returned to the unactuated state.Similarly, with an encoder 76, the micro switch 72 will set or calibratethe zero value for the encoder 76 with the microcontroller 74 every timethe handle grip 54 is released and returned to the unactuated state. Forexample, if the micro switch is closed (i.e., the hand grip is not beingpulled), the control algorithm will operate to have the motor controllersend a signal to the motor that slows down the motor to a stop.Conversely, if the micro switch is open (i.e., the hand grip is beingpulled a given amount over the threshold value), the microcontrollersees the sensor 70 output as an input for the control algorithm (e.g.,an input to the PID algorithm) to calculate the pulse width modulationvalue for the motor controller to send to the motor.

The power assist wagon 10 may also comprise a safety cut-off system 36.One embodiment of the safety cut-off system 36 is connected to thehandle 20 and is shown in FIGS. 12A-13. In one embodiment, the safetycut-off system 36 comprises another sensor 92, such as a micro switch ora momentary pushbutton switch connected to the handle 20 that senseswhen the handle 20 is in the allowable operating range of the handle 20.For example, if the handle 20 is within the allowable angle range forusage, the microcontroller 74 will be allowed to obtain signals from thesensor 70 in the control system for input into the control algorithm. Ifthe handle 20 is outside the allowable range for usage, themicrocontroller 74 will have the motor controller in the drive system 30send a zero voltage signal to the motor to prevent movement of themotor. With brushless motors, the safety mechanism may intentionally“short” the motor signal wires to create a braking action as well as azero volt signal when the micro switch is open. The relay connecting themotor signal wires may also turn off, which would prevent any signalfrom reaching the motor, or a mechanical brake could also be appliedwhen the wagon is off or the handle not in the safe angle range.

In a preferred embodiment, the handle 20 has a proximal end 94 that ispivotally connected to the wagon body 12. As shown in FIG. 12A, in oneembodiment a bracket 96, such as a U-shaped bracket 96 is connected tothe wagon body 12. In such an embodiment, the proximal end 94 of thehandle 20 is pivotally connected to the U-shaped bracket 96 about anaxis of the handle 20. An axle 98 that is transverse to a longitudinalaxis of the handle 20 and which engages the bracket 96 may be providedat the proximal end 94 of the handle 20 to provide for the pivotingmotion of the handle 20 with respect to the bracket 96 connected to thewagon body 12. In a preferred embodiment, the bracket 96 may have stops100 provided on an outer surface of the bracket 96, and a protrusion 102may extend from the axle 98 to engage the stops 100 at both extreme endsof the allowable pivoting motion of the handle 20. With reference toFIGS. 12C, 12D and 13, the total range of movement of one embodiment ofthe handle 20 is illustrated. For example, when the handle 20 is pivotedupwardly as shown in FIGS. 12C and 13 the protrusion 102 extending fromthe axle 98 will engage one of the stops 100 at approximately the 90°location of the handle 20 to prevent the handle 20 from extendingfurther toward the wagon body 12. Similarly, another stop 100 may beprovided to prevent the handle 20 from hitting the ground as shown inFIGS. 12E and 13, such as at some angle below the horizontal, forexample approximately 20° below the horizontal. Within the full range ofmotion of the handle 20 as shown in FIG. 13, there is a range of motionof the handle 20 where the drive system 30 is operable and a range ofmotion of the handle 20 where the drive system is not operable.Referring to FIG. 13, the operable range in motion of one embodiment ofthe handle 20 is from an angle α that is approximately 20° from thehorizontal axis to an angle β that is approximately 80° from thehorizontal axis. By providing that the handle 20 must be at an anglegreater than 20° from the horizontal axis helps to prevent a small childfrom activating the drive system 30. Similarly, if the angle of thehandle 20 is greater than β the microcontroller 74 will not allow thedrive system 30 to operate as another safety measure to prevent the userfrom sitting in the wagon and activating the drive system 30 and also toprevent the drive system 30 from engaging when the wagon 10 is beinglifted upwardly by the user. However, if the angle of the handle 20 isless than β but greater than α, the microcontroller 74 will allow thedrive system 30 to operate if a sufficient force is measured by thesensor 70 in the handle 20. Additionally, there may be a spring pin tocreate a small force for the user to overcome to pivot the handledownward and prevent the handle from falling toward the groundunintentionally.

In one embodiment, actuation of the micro switch sensor 92 is providedby a cam 104 in the interior of a housing 106 encasing the micro switchsensor 92 and pivot mechanism of the handle 20. The cam 104 is bestshown in FIG. 12A. The cam 104 engages a switch 108 on the micro switchsensor 92 during certain angular positions of the handle 20. Referringto FIG. 12C, the handle is at the 90° orientation and the switch 108 isopen and not engaged by the cam 104. As the handle 20 is rotateddownwardly within the operable range of motion of the handle 20, asshown in FIG. 12D, the cam 104 engages the switch 18 to close the switch108. Finally, if the handle 20 is dropped below the operable range ofmotion, as shown in FIG. 12E, the cam 104 disengages from the switch 108and the switch 108 opens again. As explained above, the state of themicro switch sensor 92 of the safety cut-off system 36 is anothervariable that the control algorithm in the microcontroller 74 utilizesto calculate a signal that is sent from the motor controller to themotor. Alternately, an angle sensor that detects the angle of the handle20 and provides a signal of the angle of the handle 20 to themicrocontroller 74 may be utilized. The angle signal may also act as aninput variable to the control algorithm. Various types of angle sensorsinclude potentiometers, proximity sensors, limit switches, etc.

As explained above, to provide the propulsion, the power assist wagon 10includes a drive system 30. The drive system 30 preferably provides arotational force to the drive wheel 16. One embodiment of a drive system30 is shown in FIGS. 14A-14C. Referring to FIGS. 14A and 20, in oneembodiment the drive system 30 includes motor controller 110, a motor112 having a pinion gear 114, a gear box 116, an output member 118 and apower transfer member 120. A gear box housing 122 may also be providedaround the gear box 116 for safety purposes to prevent access to thegears in the gear box 116. The motor controller 110 receives signalsfrom the microcontroller 74 and transmits voltages to the motor 112 tooperate the motor 112. While the motor controller and microcontrollerhave been explained as separate components, the motor controller may beintegrated into the microcontroller.

In a preferred embodiment the preferred motor 112 for the drive system30 is a PMDC or permanent magnet direct current motor, however, othertypes of motors may be utilized in the wagon 10. Some of the benefits ofa PMDC motor 112 are that the PMDC motor is fairly inexpensive, itprovides a fairly constant speed which may eliminate the need for aclutch system, it may be able to be coupled directly to the rear wheel16, and it provides very minimal resistance when the wagon 10 is pulledin a non-power assist mode. One type of PMDC motor 112 that may beutilized is either a 12 volt or 24 volt direct current motor, with aspeed of approximately 3500 rpm.

As shown in FIG. 14A, in a preferred embodiment the motor 112 is locatedwithin the wagon body 12, and most preferably within and supported by abin 124 at the rear of the wagon body 12. The rear axle 18 is supportedby the wagon frame 26 of the wagon body 12, preferably in a fixed mannerso that the rear axle 18 does not rotate. The gear box 116 may also besupported coaxially by the rear axle 18. Preferably, the pinion gear 114output of the motor 112 engages the gear box 116. In a preferredembodiment, the output member 118 at the exit of the gear box 116rotates at approximately a 1:25 ratio of the rotation of the pinion gear114. The output member 118 has a plurality of fingers 126 that engagewith receivers 128 in the power transfer member 120 to transfer rotationof the output member 1:1 with the power transfer member 120. Further,the power transfer member 120 is connected to the drive wheel 16 in a1:1 manner so that the wheel 16 rotates at a 1:1 ratio with the outputmember 118 of the drive system 30. As shown in FIG. 14B, the drive wheel16 has a plurality of ribs 130 that engage a plurality of grooves 132 inthe power transfer member 120 to transfer rotational motion of the powertransfer member 120 to the drive wheel 16. Additionally, a bushingmember 134 having a plurality of external surfaces is rotationally fixedwithin a mating bore 136 in the drive wheel 16. The bushing member 134has a bore 138 through which the rear axle extends to rotationallysupport the drive wheel 16 on the rear axle 18. Alternately, other powertransmission mechanisms may be used to transmit power from the motor 112to the rear wheel 16, including, for example, a belt drive or chaindrive between the motor drive shaft and the rear drive wheel 16. In thepreferred embodiments, the rear wheel 16 is a driven wheel through itsmechanical connection with the motor drive shaft, and the rear wheel 16is able to rotate freely on the rear axle 18. In an alternate embodimentthe rear axle 18 may be driven by the motor 112, and the rear wheel 16may be fixed, such as by keying, to the rear axle 18 such that rotationof the rear axle 18 causes rotation of the rear wheel 16.

Referring to FIGS. 15-20, one embodiment of the power system 34 isillustrated. As shown, in one embodiment the power system 34 includes arechargeable battery 140, which may, for example, be a 12 volt or 24volt lithium ion or lead acid battery. In a preferred embodiment thebattery 140 is also located within the wagon body 12, and is preferablypositioned within a battery receiver 142 in the rear bin 124. Terminals(not shown) are provided in the rear bin 124 to electrically connect thebattery 140 to the control system 32, as schematically illustrated inFIG. 20. The battery 140 may be charged when docked in the batteryreceiver 142 in the rear bin 124 as shown in FIG. 15. In a preferredembodiment, the battery 140 has a spring-loaded release member 144 thatcan be actuated to release the battery 140 from connection with thebattery receiver 142 for removal of the battery 140, as shown in FIGS.16 and 17. The battery 140 may alternately be docked in an auxiliarycharger, as shown in FIG. 18, for charging when removed from the wagon10.

As shown in FIGS. 19A, 19B and 20, wires run from various electricalcomponents to the microcontroller 74. The wires from the sensor 70 andmicro switch 72 run down the center of the handle 20 and join with thewires from the micro switch sensor 92 in the safety cut-off system 36and preferably culminate in a quick release connector 146, preferablylocated behind the housing 106 at the proximal end of the handle 20. Awiring harness 148 extends from the front of the wagon 10 to the rear ofthe wagon 10. The wiring harness 148 typically extends through the wagonbody 12, and if the wagon body 12 includes a fabric shell 28, it mayextend through a sleeve (not shown) in the wagon shell 28. The wiringharness 148 preferably has a quick release connector at one end toconnect to the quick release connector at the handle, and another quickrelease connector at the second end to connect to a quick releaseconnector extending from the bin at the rear of the wagon 10. The wirethat is in the telescoping tube should either be extremely flexible orretractable in order to accommodate the changing size of the handle.Similarly, the wire that extends through the body of the wagon must alsobe flexible to accommodate for folding of a folding wagon.

With reference to FIG. 11, there is preferably no motor output until thehandle force signal reaches a minimum load, also referred to as a setpoint. Once the minimum load is reached, meaning that the user isapplying a force to the handle 20 equal to or greater than the minimumload, the microcontroller and motor controller will operate to have themotor provide an output. An output is also calculated/provided when theforce is below the minimum load. For example, if the motor output isgreater than zero and the force is below the setpoint, themicrocontroller is still operating to have the motor provide an outputthat is lower than the previously calculated output. The microcontrollerand motor controller adjusts that motor output (voltage, duty cycle) inan attempt to maintain the handle force signal about a set point. In oneembodiment a PID (proportional-integral-derivative) loop is the controlalgorithm used by the microcontroller to control the signal to the motorcontroller and ultimately the motor. The PID controller or loop is acontrol loop feedback mechanism that continuously calculates an “errorvalue” as the difference between a measured variable, here a force, anda desired set point. The PID controller attempts to minimize the errorover time by adjusting the power supplied to the motor to operate themotor and determine a new error value, which it is attempting to driveto zero. While a PID controller is utilized in one embodiment, alternatecontrol algorithms such as a look up table, hysteresis control, fuzzylogic, etc. may be utilized to achieve the desired outcome. Once thecontrol algorithm concludes its calculations, which occurs approximatelyevery 100 milliseconds with a preferred processor, a signal, which ispreferably a pulse width modulation signal, is sent from the motorcontroller to the motor to adjust the speed of the motor. Generally, thepulse width modulation signal will range from zero volts to twelvevolts, corresponding to approximately zero miles per hour toapproximately four miles per hour of wagon speed.

In one embodiment, the control algorithm is based on one or more of thefollowing inputs: the value received from the input sensor (e.g.,encoder, hall-effect sensor, or alternate sensor), the state of themicro switch, the state of the micro switch in the safety cut-offsystem, and the current state of the motor. Additional inputs may alsobe considered. In one example, the PID algorithm is as follows:Error(t)=Encoder Value(t)−SetpointPWM Value=P*Error(t)+∫Error(t)*dt+D*(Error(t)/dt)

The setpoint, P, I and D are all constants that are determined by theoverall system through testing. The setpoint is the encoder value thatcorresponds to a predetermined force. For example, if it is desired thatthe user pull the wagon with a maximum of 2 lbs. of force, the encodervalue that corresponds to 2 lbs. of force is the setpoint. While anencoder is described in this section, any sensor data may be utilized.The goal of the PID algorithm and overall system is to speed up and slowdown the motor and the wagon so that the user is always pulling no morethan a certain pounds of force at any given speed, load or terrain.

In addition to a PID algorithm, the system may utilize a look up tableand a different algorithm. For example, if the system is on and thehandle angle is determined to be in the acceptable range, the motoroutput will initially be set to 0%. The micro switch in the handle gripwill be analyzed to determine if it is open or closed. The encodervalues will be obtained, an average will be calculated, the average willbe compared against the look up table values, and the motor output ratechange will be determined. Preferably, the motor output rate change willbe added to prior output values, such as for example the prior fifteenvalues, with each subsequent iteration requiring the dropping of theoldest output value in an indexing manner. In this manner the outputvalue will generally be smoothed over time. The lookup table ispreferably utilized to determine a motor output rate change based on theaverage encoder value that is calculated after each iteration. If thecalculated encoder value is around a desired set point the motor outputwill not be changed in an attempt to maintain a steady state cruisingvalue. If the calculated encoder value is above the desired set pointthe motor output rate change will increase depending on how great thecalculated encoder value is above the desired set point. And, if thecalculated encoder value is below the desired set point, the motoroutput rate change will decrease as not as much assistance from themotor is needed. If the calculated encoder value is zero or if the microswitch is determined to be closed, the motor output change rate willdecrease drastically as it is likely determined that the user hasstopped.

Several alternative embodiments and examples have been described andillustrated herein. A person of ordinary skill in the art wouldappreciate the features of the individual embodiments, and the possiblecombinations and variations of the components. A person of ordinaryskill in the art would further appreciate that any of the embodimentscould be provided in any combination with the other embodimentsdisclosed herein. Additionally, the terms “first,” “second,” “third,”and “fourth” as used herein are intended for illustrative purposes onlyand do not limit the embodiments in any way. Further, the term“plurality” as used herein indicates any number greater than one, eitherdisjunctively or conjunctively, as necessary, up to an infinite number.Additionally, the term “having” as used herein in both the disclosureand claims, is utilized in an open-ended manner.

It will be understood that the disclosed embodiments may be embodied inother specific forms without departing from the spirit or centralcharacteristics thereof. The present examples and embodiments,therefore, are to be considered in all respects as illustrative and notrestrictive, and the disclosed embodiments are not to be limited to thedetails given herein. Accordingly, while the specific embodiments havebeen illustrated and described, numerous modifications come to mindwithout significantly departing from the spirit of the disclosure andthe scope of protection is only limited by the scope of the accompanyingClaims.

What is claimed is:
 1. A power assist system for a wagon, comprising: awagon body, the wagon body having a plurality of wheels connectedthereto, at least one of the plurality of wheels being a driven wheel; ahandle having a distal end and a proximal end, the proximal end of thehandle being pivotally connected to the wagon body; a handle gripadjacent a distal end of the handle; a control system in one of thehandle and the handle grip, the control system comprising a sensor tosense a load being applied to the handle grip that moves at least aportion of the handle grip axially with respect to the proximal end ofthe handle; a drive system comprising a motor mechanically connected tothe driven wheel; and, a microcontroller obtaining an input signal fromthe control system and providing an output signal to the drive system toselectively drive the driven wheel of the wagon.
 2. The power assistsystem of claim 1, wherein the control system comprises a sensor todetermine a load applied to the handle grip, wherein the load must begreater than a predetermined minimum threshold above zero pounds for thedrive system to provide initial propulsion to the drive wheel.
 3. Thepower assist system of claim 2, further comprising a micro switch aspart of the control system, the micro switch being opened when a loadgreater than a predetermined minimum threshold above zero pounds isapplied to the handle grip, the micro switch being closed when a loadless than the predetermined minimum threshold is applied to the handle,the microcontroller obtaining a signal from the micro switch as towhether the micro switch is open or closed.
 4. The power assist systemof claim 2, further comprising a spring adjacent the distal end of thehandle, wherein the spring provides a force that must be overcome forthe handle grip to move axially with respect to the proximal end of thehandle.
 5. The power assist system of claim 1, further comprising asafety cut-off system connected to the handle, the safety cut-off systemcomprising a safety-control switch electrically connected to themicrocontroller, the microcontroller adjusting the signal sent to thedrive system based on a state of the safety-control switch.
 6. The powerassist system of claim 5, wherein the signal sent to the drive system isa zero volt signal when the safety-control switch is open.
 7. The powerassist system of claim 5, wherein the microcontroller turns off thedrive system when the handle is below a preset angle and when the handleis above a preset angle.
 8. The power assist system of claim 5, whereinthe safety cut-off switch is adjacent the proximal end of the handle. 9.The power assist system of claim 1, further comprising a rechargeablebattery connected to the wagon, the battery providing a source of powerfor the drive system.
 10. The power assist system of claim 9, whereinthe battery is removable from the wagon, and wherein the battery can berecharged on an auxiliary charger separate from the wagon.
 11. The powerassist system of claim 1, further comprising a remaining battery lifeindicator on the handle.
 12. The power assist system of claim 1, whereinthe drive system comprises a motor and a motor controller, and whereinthe motor controller sends a signal to the motor to control output ofthe motor.
 13. The power assist system of claim 12, further comprisingan on/off switch, wherein the motor is electrically disconnected fromthe motor controller when the on/off switch is in the off state.
 14. Thepower assist system of claim 1, wherein the signal from the motorcontroller ranges from approximately zero volts to approximately twelvevolts.
 15. A power assist system for a wagon, comprising: a wagon body,the wagon body having a plurality of wheels connected thereto, at leastone of the plurality of wheels being a driven wheel; the driven wheelrotatingly connected to an axle; a drive system comprising a motormechanically connected to the driven wheel, the drive system furthercomprising a motor controller electrically connected to the motor; ahandle having a distal end and a proximal end, the proximal end of thehandle being pivotally connected to the wagon body; a handle gripadjacent a distal end of the handle, the handle grip having an internalsensor; and, a microcontroller electrically connected to the sensor andthe motor controller, the microcontroller obtaining a signal from thesensor, and based on the signal from the sensor the microcontrollersending a signal to the motor controller to speed up or slow down themotor.
 16. The power assist system of claim 15, wherein the sensorwithin the handle senses an axial load being applied to the handle by auser.
 17. The power assist system of claim 15, wherein to provide aninitial signal to the motor to speed up the sensor must sense a loadgreater than a predetermined minimum threshold above zero pounds.